WO2019136530A1 - Apparatus for manufacturing a container - Google Patents

Apparatus for manufacturing a container Download PDF

Info

Publication number
WO2019136530A1
WO2019136530A1 PCT/AU2019/050023 AU2019050023W WO2019136530A1 WO 2019136530 A1 WO2019136530 A1 WO 2019136530A1 AU 2019050023 W AU2019050023 W AU 2019050023W WO 2019136530 A1 WO2019136530 A1 WO 2019136530A1
Authority
WO
WIPO (PCT)
Prior art keywords
tube
base
apparatus defined
forward end
unit
Prior art date
Application number
PCT/AU2019/050023
Other languages
French (fr)
Inventor
Darren John WILLIAMES
Original Assignee
Auzfresh Holdings Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2018900115A external-priority patent/AU2018900115A0/en
Application filed by Auzfresh Holdings Pty Ltd filed Critical Auzfresh Holdings Pty Ltd
Priority to US16/961,924 priority Critical patent/US11420400B2/en
Priority to EP19738420.9A priority patent/EP3740371A4/en
Priority to AU2019207533A priority patent/AU2019207533A1/en
Publication of WO2019136530A1 publication Critical patent/WO2019136530A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/36—Bending and joining, e.g. for making hollow articles
    • B29C53/38—Bending and joining, e.g. for making hollow articles by bending sheets or strips at right angles to the longitudinal axis of the article being formed and joining the edges
    • B29C53/40—Bending and joining, e.g. for making hollow articles by bending sheets or strips at right angles to the longitudinal axis of the article being formed and joining the edges for articles of definite length, i.e. discrete articles
    • B29C53/46—Bending and joining, e.g. for making hollow articles by bending sheets or strips at right angles to the longitudinal axis of the article being formed and joining the edges for articles of definite length, i.e. discrete articles using external forming surfaces, e.g. sleeves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B43/00—Forming, feeding, opening or setting-up containers or receptacles in association with packaging
    • B65B43/08—Forming three-dimensional containers from sheet material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/80—Component parts, details or accessories; Auxiliary operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • B29C65/7832—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the overlap between the parts to be joined, e.g. the overlap between sheets, plates or web-like materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B29C65/7847—Holding or clamping means for handling purposes using vacuum to hold at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2422—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical
    • B29C66/24221—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical being circular
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/345—Progressively making the joint, e.g. starting from the middle
    • B29C66/3452—Making complete joints by combining partial joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4322—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms by joining a single sheet to itself
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • B29C66/53461—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/61—Joining from or joining on the inside
    • B29C66/612—Making circumferential joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81463—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/851—Bag or container making machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B41/00—Supplying or feeding container-forming sheets or wrapping material
    • B65B41/02—Feeding sheets or wrapper blanks
    • B65B41/04—Feeding sheets or wrapper blanks by grippers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B41/00—Supplying or feeding container-forming sheets or wrapping material
    • B65B41/12—Feeding webs from rolls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D3/00—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines
    • B65D3/02—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines characterised by shape
    • B65D3/04—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines characterised by shape essentially cylindrical
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D3/00—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines
    • B65D3/10—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines characterised by form of integral or permanently secured end closure
    • B65D3/12—Flanged discs permanently secured, e.g. by adhesives or by heat-sealing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0081—Shaping techniques involving a cutting or machining operation before shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B5/00—Packaging individual articles in containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, jars
    • B65B5/06—Packaging groups of articles, the groups being treated as single articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B51/00—Devices for, or methods of, sealing or securing package folds or closures; Devices for gathering or twisting wrappers, or necks of bags
    • B65B51/10—Applying or generating heat or pressure or combinations thereof
    • B65B51/22—Applying or generating heat or pressure or combinations thereof by friction or ultrasonic or high-frequency electrical means, i.e. by friction or ultrasonic or induction welding
    • B65B51/225—Applying or generating heat or pressure or combinations thereof by friction or ultrasonic or high-frequency electrical means, i.e. by friction or ultrasonic or induction welding by ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B7/00—Closing containers or receptacles after filling
    • B65B7/16—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons
    • B65B7/28—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons by applying separate preformed closures, e.g. lids, covers
    • B65B7/2842—Securing closures on containers
    • B65B7/2878—Securing closures on containers by heat-sealing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D59/00—Plugs, sleeves, caps, or like rigid or semi-rigid elements for protecting parts of articles or for bundling articles, e.g. protectors for screw-threads, end caps for tubes or for bundling rod-shaped articles
    • B65D59/02—Plugs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D59/00—Plugs, sleeves, caps, or like rigid or semi-rigid elements for protecting parts of articles or for bundling articles, e.g. protectors for screw-threads, end caps for tubes or for bundling rod-shaped articles
    • B65D59/04—Sleeves, e.g. postal tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
    • B65D85/30—Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure
    • B65D85/34—Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure for fruit, e.g. apples, oranges or tomatoes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2301/00—Handling processes for sheets or webs
    • B65H2301/40—Type of handling process
    • B65H2301/41—Winding, unwinding
    • B65H2301/419—Winding, unwinding from or to storage, i.e. the storage integrating winding or unwinding means
    • B65H2301/4193—Winding, unwinding from or to storage, i.e. the storage integrating winding or unwinding means for handling continuous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H27/00—Special constructions, e.g. surface features, of feed or guide rollers for webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2801/00—Application field
    • B65H2801/81—Packaging machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H5/00—Feeding articles separated from piles; Feeding articles to machines
    • B65H5/06—Feeding articles separated from piles; Feeding articles to machines by rollers or balls, e.g. between rollers
    • B65H5/062—Feeding articles separated from piles; Feeding articles to machines by rollers or balls, e.g. between rollers between rollers or balls
    • B65H5/064—Feeding articles separated from piles; Feeding articles to machines by rollers or balls, e.g. between rollers between rollers or balls the axes of the rollers being perpendicular to the plane of the articles

Definitions

  • the present invention relates to an apparatus for manufacturing a container that is suitable particularly although not exclusively for packaging and transporting perishable produce, such as fruit.
  • the present invention also relates to a method of manufacturing the container.
  • the present invention also relates to the container.
  • the invention relates particularly to containers of the type that comprise a side wall in the form of a tube, a base at one end of the tube, and a removable lid at the other end of the tube.
  • the invention relates particularly to containers of the type that comprise a side wall in the form of a tube such as a cylindrical tube made from a plastics material, a base made from a plastics material that is welded or otherwise connected to one end of the tube, and a removable lid that is typically made from a plastics material and is adapted to be inserted into and removed from the other end of the tube to allow access to the contents of the container.
  • a side wall in the form of a tube such as a cylindrical tube made from a plastics material, a base made from a plastics material that is welded or otherwise connected to one end of the tube, and a removable lid that is typically made from a plastics material and is adapted to be inserted into and removed from the other end of the tube to allow access to the contents of the container.
  • the invention provides an apparatus and a method for manufacturing these containers that is an alternative to currently-available apparatus and methods.
  • the present invention provides an apparatus for manufacturing a container that includes a side wall in the form of a tube and a base at one end of the tube.
  • the apparatus includes:
  • a tube forming unit for progressively folding a length of a sheet of a side wall material into an elongate tube shape having a forward end for receiving a base of the container and welding together lengthwise extending sides of the sheet to form the tube; and (b) a base attachment unit for positioning a base of the container on the forward end of the tube.
  • the apparatus may also include a control system for moving the base and the tube so that that the forward end of the tube is in a required base receiving position to receive the base.
  • the apparatus may also include an end welding unit for welding the base to the forward end of the tube.
  • the end welding unit may be any suitable welding unit.
  • the end welding unit may be an ultrasonic welding unit.
  • the end welding unit may be a thermal welding unit.
  • the end welding unit may be adapted to weld the base and the forward end of the tube together at a single location or multiple locations around the perimeter of the forward end of the tube .
  • the end welding unit may be adapted to weld the base and the forward end of the tube together with a continuous weld around the perimeter of the forward end of the tube.
  • the base and/or the forward end of the tube may be formed so that the base and the tube mechanically interlock together when the base is positioned on the forward end of the tube.
  • the mechanical interlock may be via friction engagement.
  • the base may be adapted, such as by including a perimeter flange, to be inserted into or inserted over the forward end of the tube.
  • the base attachment unit may include a base loading head for picking up the base from a base feed position and supporting the base and releasing the base when the base is positioned on the forward end of the tube.
  • the base loading head may be adapted to contact the base at the feed position and apply at least a partial vacuum to the base that retains the base to the head.
  • the base attachment unit may also include a feed assembly for supporting a stack of bases and delivering each base in turn to the base feed position.
  • the feed assembly may be a standard de-nesting unit designed to deliver a single base from a nested stack of bases.
  • the feed assembly may be positioned so that the stack is a vertical or an inclined stack to facilitate gravity feeding bases downwardly from a higher feed end of the stack to the base feed position of the stack.
  • the base attachment unit may also include a drive assembly for moving the base loading head and the base from the base feed position to the forward end of the tube and for returning the base loading head (without the base) from the forward end of the tube to the base feed position.
  • the drive assembly may be adapted to move the base loading head in a linear path away from the feed position to a base loading position.
  • the drive assembly may be adapted to move the base loading head in any other suitable path away from the feed position to the base loading position
  • the drive assembly may be adapted to pivot the base loading head from the base loading position to position the base on the forward end of the tube at the base receiving position.
  • the drive assembly may include an indexing unit for moving the base loading head in a series of steps in the above-described pathway between the base loading position and the base receiving position.
  • the base attachment unit may include an assembly for holding the forward end of the tube so that the tube has a required transverse cross-section, such as a circular transverse cross-section in the case of a cylindrical tube, while each base is positioned on the forward end of the tube.
  • the purpose of the holding assembly is to ensure that the cross-section of the forward end of the tube is the correct cross-section for the base.
  • the purpose of the holding assembly is to ensure that the forward end of the tube has a circular cross-section, rather than an oblong or other cross-section, so that the cross-section is correct for the base. This is particularly important in situations whether the base is formed, for example with a perimeter flange, to be inserted into the forward end of the tube.
  • the holding assembly may include two holding units that are movable inwardly toward and outwardly away from the forward end of the tube, each holding unit including a surface that defines one-half of a required outer perimeter of the tube so that, in use, the surfaces are moved to contact the forward end of the tube and ensure that the tube has a required transverse cross-section, such as a circular cross-section in the case of a cylindrical tube, while each base is positioned on the forward end of the tube.
  • the tube forming unit may include:
  • a series of lengthwise spaced-apart tube folding elements such as pairs of rollers or other suitable elements, for progressively folding the sheet material into a tube having a required transverse cross-section with side edges of the sheet material in contact along the length of the tube, and
  • a seam welding unit for progressively welding the side edges of the sheet material together and forming an elongate seam of the tube.
  • the drive assembly may comprise an indexing unit for moving the side wall sheet material and the tube through the tube forming unit in a series of steps to the base receiving position.
  • the indexing unit may be adapted to for moving the side wall sheet material and the tube a set required length or between index marks.
  • the seam welding unit may be any suitable welding unit.
  • the seam welding unit may be an ultrasonic welding unit.
  • the seam welding unit may be a thermal welding unit.
  • the tube folding elements may be adapted to form the tube with overlapping side edges.
  • the tube folding elements may include a pair of lengthwise spaced-apart guide roller units for guiding the tube to the seam welding unit.
  • Each guide roller unit may include (i) a first set of guide rollers for contacting the outer surface of the tube and locating and guiding the tube, (ii) a first support arm supporting each first guide roller for rotation about an axis in response to contact of the first guide roller with the tube as the tube moves through the guide roller unit, and (iii) an adjustment assembly for moving each first support arm radially inwardly and outwardly between an inner position and an outer position to adjust the size of the opening for the tube.
  • This arrangement makes it possible to use the guide roller unit with a range of different sizes of the cross-sections of the tubes.
  • the first guide rollers are arranged at spaced intervals around a perimeter that is transverse to the direction of movement of the tube and define an opening within the perimeter through which the tube moves.
  • Each guide roller unit may include:
  • the adjustment assembly for each first guide roller may include (i) a coupling pin extending outwardly from the first support arm of the first guide roller and (ii) a plurality of spiral grooves in the rotatable outer support plate that receive the coupling pins of the first guide rollers, with each spiral groove extending between an inner end and an outer end that is located outwardly of the inner end, whereby rotation of the outer support plate relative to the inner support plate causes the coupling pins to move along the spiral grooves and thereby outwardly or inwardly and thereby moves the first support arms and the first guide rollers radially between the inner and the outer positions so that the size of the opening defined by the first guide rollers can be selected, and (c) a locking assembly for locking the inner support plate and the outer support plate together to fix the radial position of the first guide rollers and thereby fix the size of the opening.
  • Each guide roller unit may include a second set of the guide rollers and support arms adjacent the first set of guide rollers and support arms, whereby the first and the second sets of the guide rollers locate and guide the tube.
  • the double set of guide rollers is advantageous in terms of ensuring there is a stable tube diameter and that the tube is guided accurately.
  • the inner support plate may include a plurality of second elongate channels extending radially outwardly from the central opening that receive and guide the second support arms and thereby the second guide rollers for radial movement between the inner and the outer positions.
  • the other outer support plate may be mounted so that it can rotate relative to the inner support plate
  • the adjustment assembly for each second guide roller may include a coupling pin extending outwardly from each second support arm and a plurality of spiral grooves in the other outer support plate that receive the coupling pins, with each spiral groove extending between an inner end and an outer end that is located outwardly of the inner end, whereby rotation of the outer support plate relative to the inner support plate causes the coupling pins to move along the spiral grooves and thereby outwardly or inwardly and thereby moves the second support arms and the second guide rollers radially between the inner and the outer positions so that the size of the opening defined by the first guide rollers can be selected.
  • the second guide rollers may be off-set in relation to the first guide rollers around the perimeters of the guide rollers. This feature allows the guide rollers to maximise contact with the tube around the perimeter of the tube. This is an important consideration for larger diameter tubes.
  • the tube folding elements may include a seam adjustment assembly.
  • the seam adjustment assembly may include a pair of gripper elements, with each gripper element being formed to engage a side edge of the sheet and to push the side edges apart to form the seam with a required overlap and to keep seam in a position that is aligned with the downstream seam welding unit.
  • the seam adjustment assembly may include a support assembly that supports the gripper elements for movement away from and towards each other to adjust the overlap.
  • the seam adjustment assembly may include any suitable means for applying a required biasing force to the gripper elements.
  • the seam adjustment assembly may include a fluid- actuated, typically an air-actuated, assembly for acting against the gripper elements and moving the gripper elements towards and away from each other.
  • the fluid-actuated assembly applies the same pressure to both gripper elements and moves the gripper elements uniformly while keeping the seam in a central position.
  • a benefit of this arrangement is that different width sheets does not affect the operation of the gripper elements, and the gripper elements are able to automatically accommodate different width sheets, with consequential changes in seam width for a given diameter tube, with the seam remaining in a positioned that is aligned with the downstream seam welding unit.
  • the seam adjustment assembly may include an assembly for moving the gripper elements laterally with respect to the direction of movement of the tube to facilitate aligning the seam with the downstream seam welding unit.
  • the seam adjustment assembly may be positioned between the pair of guide roller units.
  • the guide roller units have a large contact area, it allows more pressure to be applied by the gripper elements. This reduces the accuracy required to position the gripper elements.
  • the apparatus may further include a cutting unit for cutting the tube a required distance from the forward end of the tube after the base has been positioned on and welded to the forward end of the tube, thereby forming a tube of a required length with an inserted base and forming the new forward end of the tube for receiving another base.
  • a cutting unit for cutting the tube a required distance from the forward end of the tube after the base has been positioned on and welded to the forward end of the tube, thereby forming a tube of a required length with an inserted base and forming the new forward end of the tube for receiving another base.
  • the cutting unit may include a shear blade.
  • the transverse cross-section of the tube may be any suitable cross-section.
  • the transverse cross-section of the tube may be circular whereby the tube is a cylindrical tube.
  • the transverse cross-section of the tube may be square.
  • the base may include a base panel for closing the forward end of the tube and a perimeter flange that extends from the base panel.
  • the perimeter flange may be adapted to be inserted into the forward end of the tube.
  • the perimeter flange may include a lead-in edge to facilitate insertion of the flange into the forward end of the tube.
  • the perimeter flange may be adapted to be positioned over the forward end of the tube.
  • the base may be made from any suitable material.
  • the base may be made from a plastics material.
  • the side wall sheet material may be a plastics material.
  • the side wall sheet material may be a transparent plastics material.
  • the present invention also provides a method of manufacturing a container that comprises a side wall in the form of a tube and a base at one end of the tube that comprises:
  • the method may include welding together the base and the forward end of the tube.
  • the method may include mechanically interlocking together the base and the forward end of the tube.
  • the method may include holding the forward end of the tube so that the tube has a required transverse cross-section, such as a circular transverse cross-section in the case of a cylindrical tube, while each base is positioned on the forward end of the tube.
  • the apparatus and the method may be suitable by way of example for manufacturing a container for packaging and transporting perishable produce, such as fruit.
  • the apparatus and the method are not confined to this application.
  • the present invention also provides a guide roller unit per se for guiding a lengthwise folded tube of sheet material to a seam welding unit includes (i) a first set of guide rollers for contacting an outer surface of the tube and locating and guiding the tube, (ii) a first support arm supporting each first guide roller for rotation about an axis in response to contact of the first guide roller with the tube as the tube moves through the guide roller unit, and (iii) an adjustment assembly for moving each first support arm radially inwardly and outwardly between an inner position and an outer position to adjust the size of the opening for the tube.
  • the first guide rollers may be arranged at spaced intervals around a perimeter that is transverse to the direction of movement of the tube and define an opening within the perimeter through which the tube moves.
  • Each guide roller unit may include:
  • Figure 1 is a perspective view on one embodiment of a container in accordance with the invention
  • Figure 2 is a side view of the container shown in Figure 1;
  • Figure 3 is a top view of the base of the container shown in Figure 1;
  • Figure 4 is a cross-section of the base component along the line C-C of Figure 3;
  • Figure 5 is a perspective view of one embodiment of an apparatus for manufacturing the cylindrical tube of the container shown in Figures 1 and 2 and positioning the container base shown in Figures 3 and 4 on an end of the tube;
  • Figure 6 is a top view of the apparatus shown in Figure 5;
  • Figure 7 is a side view of the apparatus shown in Figure 5;
  • Figure 8 is a side view of section of the apparatus shown in Figure 5 that includes a pair of guide roller units and a seam adjustment assembly positioned between the guide roller units;
  • Figure 9 is a section along the line 9-9 of Figure 8.
  • Figure 10 is a perspective view of one of the guide roller units of the apparatus shown in Figure 5;
  • Figure 11 is an exploded perspective view of the guide roller unit shown in
  • Figure 12 is a perspective view in diagrammatic form of the section of the apparatus shown in Figure 5 at the forward end of the apparatus which shows the tube holding assembly of the base attachment unit of the apparatus;
  • Figure 13 is an end view of Figure 12 with the holding assembly in an open position
  • Figure 14 is a series of end views of Figure 12 that illustrates how the holding assembly corrects different out-of-shape tube cross-sections
  • Figure 15 is an enlarged perspective view of the end of the apparatus shown in Figure 4 which illustrates the base attachment unit of the apparatus in an operative position in which the unit has positioned a base on the end of a cylindrical tube;
  • Figures 16-24 show how the base attachment unit of the apparatus picks up and moves a base from a stack and positions the base on an end of a cylindrical tube and welds the base to the tube, with:
  • Figures 16 and 17 being respective perspective and side views that show a loading head of the base attachment unit picking up the base from the stack of bases
  • Figures 18 and 19 are respective perspective and side views that show the loading head with retained base a part of the way along a linear path to a loading position for the base;
  • Figures 20 and 21 are respective perspective and side views that show the loading head with the retained base at the loading position
  • Figures 22 and 23 are respective perspective and side views that show the base on the end of the cylindrical tube and the base being welded to the end of the tube after the loading head has been pivoted from the loading position shown in Figures 20 and 21 to the position shown in Figures 20 and 21; and
  • Figure 24 is a side view of the loading head pivoted back to the loading position with the base and the cylindrical tube ready to be transported from the apparatus.
  • the embodiment of the container 3 of the invention shown in Figures 1 and 2 is suited by way of example for packaging and transporting perishable produce, such as fruit.
  • the container 3 has three main components, namely a side wall in the form of a cylindrical tube 5 made from a plastics material, a base 7 made from a plastics material welded to and closing one end of the tube 5, and a lid 9 made from a plastics material that closes the other end of the tube 5 and can be removed to allow access to the contents of the tube 5 and re-inserted to re-close the container 3.
  • the components are formed separately and are assembled together.
  • the base 7 is shown in detail in Figures 3 and 4.
  • the base 7 includes a circular base panel 11 for closing the base end of the tube 5 and a continuous perimeter flange 13 that extends from the base panel 11 and extends into the base end of the tube 5 and is welded to the tube 5.
  • the invention is concerned particularly with assembling the tube 5 and the base 7 together.
  • FIG. 5-7 An embodiment of the apparatus for assembling the tube 5 and the base 7 together is shown in Figures 5-7.
  • Figures 8 and 9 show a seam adjustment unit of the apparatus.
  • Figures 10 and 11 show guide roller units of the apparatus.
  • Figures 12-14 show a tube holding assembly of the base attachment unit.
  • Figures 15-24 show how a base attachment unit of the apparatus picks up and moves a base 7 from a stack of bases and positions the base on an end of a cylindrical tube formed in the apparatus and welds the base 7 to the tube.
  • the seam adjustment unit, the guide roller units, and the tube holding assembly are important features of the embodiment.
  • the embodiment of the apparatus shown in Figures 5-7 comprises:
  • an end welding unit 31 for ultra-sonic welding the base 7 to the forward end 23 of the tube 21 at three locations around the perimeter of the tube 21 at the base receiving position.
  • the apparatus also comprises a control system for moving the base 7 and the tube 21 so that that the forward end 23 of the tube is at the required base receiving position when the base 7 has reached this position and can receive the base 7.
  • the tube forming unit 15 comprises:
  • a drive assembly (not shown) for transporting the sheet 19 and the tube 21 formed from the material through the tube forming unit 15 to the base receiving position;
  • a seam adjustment assembly 67 positioned between the guide roller units 65 for controlling the overlap of the side edges 37 of the sheet 19 in the tube 21 and the position of the overlap in relation to the downstream ultra-sonic seam welding unit 39 - see below;
  • the drive assembly may be any suitable assembly that comprises an indexing unit (not shown) that moves the sheet 19 and the tube 21 in a series of steps of a required length through the tube forming unit 15.
  • the seam adjustment assembly 67 includes a pair of gripper elements 75 that, in use, engage the side edges 37 of the sheet.
  • Each gripper element 75 is formed to engage a side edge 37 of the sheet 19 in the folded tube 21 and to push the side edges 37 outwardly to form the seam with a required overlap and to form and hold the seam in a position that is aligned with the downstream seam welding unit 39.
  • the gripper elements 75 are L-shaped elements with hooked-ends that, in use, engage the side edge 37 of the sheet and push the sheet 19 outwardly.
  • the seam adjustment assembly 67 also includes a support assembly generally identified by the numeral 79 that supports the gripper elements 75 for movement away from and towards each other to adjust the overlap. The away movement is illustrated by the arrows in Figure 19.
  • the seam adjustment assembly also includes a fluid-actuated, typically an air- actuated, assembly for acting against the gripper elements 75 and moving the gripper elements 75 towards and away from each other in the directions of the arrows in Figure 9.
  • a fluid-actuated typically an air- actuated, assembly for acting against the gripper elements 75 and moving the gripper elements 75 towards and away from each other in the directions of the arrows in Figure 9.
  • the seam adjustment assembly may include springs or any other suitable options to applying a required biasing force to the gripper elements 75.
  • the fluid-actuated assembly supplies fluid, such as air, under a predetermined pressure to the chamber 83, and the fluid pressure holds the gripper elements 75 apart and maintains the position of the overlapping seam. This is important in terms of the downstream seam-welding operation.
  • Changing the pressure of the fluid to the fluid-actuated assembly makes it possible to adjust the tension applied to the sheet by the gripper elements 75. This is important to be able to accommodate different-width sheets to form a given diameter tube 21. A benefit of this arrangement is that different-width sheets does not affect the operation of the gripper elements 75, and the gripper elements 75 are able to automatically accommodate different width sheets, with consequential changes in seam width for a given diameter tube, with the seam remaining in a position that is aligned with the downstream seam welding unit.
  • the seam adjustment assembly also includes an assembly generally identified by the numeral 123 for moving the support assembly 79 and the gripper elements 75 laterally with respect to the direction of movement of the tube 21.
  • the assembly 123 includes a shaft 125 that is supported for sliding movement laterally, i.e. towards the left or the right in Figure 9 and can be locked in place in a required position.
  • the assembly 123 also includes a body 127 that is mounted to the shaft 125 and moves with the shaft 125.
  • the support assembly 79 and the gripper elements 75 are mounted on and move with the body 127. It can be appreciated that, in use, sliding lateral movement of the shaft 125 adjusts the lateral position of the seam to make it possible that the seam is aligned with the downstream seam welding unit 39.
  • the seam adjustment assembly 67 is positioned between the pair of guide roller units 65. With this arrangement, because the guide roller units 65 have a large contact area, it is possible to apply more pressure to the gripper elements 75.
  • each guide roller unit 65 includes:
  • a first set of guide rollers 85 i.e. first guide rollers
  • first guide rollers 85 for contacting the outer surface of the tube 21 and locating and guiding the tube 21 as it passes through an opening 91 defined by the first guide rollers 85
  • a first support arm 87 (see Figure 11) supporting each first guide roller 85 for free rotation about an axis (not shown) in response to contact of the first guide roller 85 with the tube 21 as the tube 21 moves through the guide roller unit 65, and
  • each first support arm 87 radially inwardly and outwardly between an inner position and an outer position to adjust the size of the opening for the tube - this arrangement making it possible to use the guide roller unit 65 with a range of different sizes of the cross-sections of the tubes 21.
  • the first guide rollers 85 are arranged at spaced intervals around a perimeter that is transverse to the direction of movement of the tube 21 (this direction is indicated by the arrow in Figure 10) and define the above-mentioned opening 91 within the perimeter through which the tube 21 moves in use of the apparatus.
  • Each guide roller unit 65 includes:
  • an inner support plate 93 with a central opening 95 for the tube 21 to pass through and a plurality of first elongate straight channels 97 extending radially outwardly from the central opening 95, with the first elongate channels 97 receiving and guiding the first support arms 87 and thereby the first guide rollers 85 for radial movement between the retracted and the extended positions; and (b) a pair of outer support plates 99, 101 on opposite sides of the inner support plate, 93.
  • the outer support plates 99, 101 are each mounted so that they can rotate relative to the inner support plate 93.
  • the outer support plates 99, 101 can also be locked in a fixed position in relation to the inner support plate 93, as described further below
  • the adjustment assembly for each first guide roller 85 includes (i) a coupling pin 103 extending outwardly from the first support arm 87 of the first guide roller 85 and (ii) a plurality of spiral grooves 105 in the outer support plate 99 that receive the coupling pins 103, with each spiral groove 105 extending between an inner end 107 and an outer end 108 that is located outwardly of the inner end 107.
  • rotation of the outer support plate 99 relative to the inner support plate 93 causes the coupling pins 103 to move along the spiral grooves 105 and thereby outwardly or inwardly (depending on the direction of rotation) and thereby moves the first support arms 87 and the first guide rollers 85 radially between the inner and the outer positions.
  • the adjustment assembly for each first guide roller 85 also includes a locking assembly (described further below) for locking the inner support plate 93 and the outer support plate 99 together, thereby to fix the radial position of the first guide rollers 85 and thereby fix the size of the opening 91.
  • Each guide roller unit 65 also includes a second set of the guide rollers 109 (second guide rollers 109) and support arms 111.
  • the second guide rollers 109 are adjacent to and radially off-set from the first guide rollers 85 and support arms 87.
  • the radial off-set of the first and second guide rollers 85, 109 can best be seen in Figure 10.
  • the first and the second guide rollers 85, 109 cooperate together to locate and guide the tube 21.
  • the double set of guide rollers 85, 109 is advantageous in terms of ensuring there is a stable tube diameter and that the tube is guided accurately.
  • the inner support plate 93 includes a plurality of second elongate straight channels 113 extending radially outwardly from the central opening 95 that receive and guide the second support arms 111 and thereby the second guide rollers 109 for radial movement between the inner and the outer positions.
  • the outer support plate 101 is mounted so that it can rotate relative to the inner support plate 93.
  • each second guide roller 109 includes a coupling pin 115 extending outwardly from each second support arm 111 and a plurality of spiral grooves (not visible in Figure 11 - but the same as the grooves 105) in the outer support plate 101 that receive the coupling pins 115, with each spiral groove extending between an inner end and an outer end that is located outwardly of the inner end, whereby rotation of the outer support plate 101 relative to the inner support plate 93 causes the coupling pins 115 to move along the spiral grooves and thereby outwardly or inwardly and thereby moves the second support arms 111 and the second guide rollers 109 radially between the inner and the outer positions so that the size of the opening 91 defined by the second guide rollers 109 can be selected.
  • the two sets of rollers 85, 109 increases the contact along the length of the tube 21.
  • the radial off-set of the first guide rollers 85 and the second guide rollers 109 allows the guide rollers 85, 109 to maximise contact with around the perimeter of the tube 21.
  • the physical size of the rollers limits the number of rollers that can be fitted around the perimeter. Maximising perimeter contact is an important consideration for larger diameter tubes.
  • the locking assembly comprises a pair of lockable handles 107 that cooperate with part-circular-shaped slots 119 in the inner plate 99 and another pair of lockable handles 107 that cooperate with part- circular-shaped slots 119 in the outer plate 101.
  • the locking handles 107 hold the outer plates 99, 101 in position in relation to the inner plate 93. Therefore, in use, with the locking handles disengaged, the outer plates 99, 101 are rotated relative to the inner plate 91 to select the required diameter for the openings 91. At this point, the locking handles 107 are engaged to fix the outer plates 99, 101 to the inner plate 93 and thereby fix the diameter of the openings 91.
  • the base attachment unit 17 includes an assembly generally identified by the numeral 69 for holding the forward end 23 of the tube 21 so that the tube 21 has a required circular transverse cross-section while each base 7 is positioned on the forward end 23 of the tube 21.
  • the holding assembly 69 is positioned at the downstream end of the apparatus and is not shown specifically in Figures 5-7 and 15 because it is obscured by other units at that end of the apparatus.
  • the purpose of the holding assembly 69 is to ensure that the cross-section of the forward end 23 of the tube 21 is the correct cross-section for the base 7.
  • the holding assembly 69 includes two holding units in the form of clamps 71 that are movable inwardly toward and outwardly away from the tube 21.
  • Each holding unit 71 has a semi-circular surface 73 that defines one-half of a required outer surface of the tube 21 so that, in use, the surfaces 73 are moved to contact the outer surface of the tube 21 at the forward end 23 of the tube 21 and form around the tube 21 and bias the tube 21 into a required circular cross-section.
  • FIG. 14 shows diagrammatically how the inwardly-moving holding units 71 bias the out-of-round shapes in Figures 14(a) and 14(b) into the required circular cross-section shape shown in Figure 14(c).
  • the movement of the holding units 71 is illustrated by the inwardly directed arrows shown in Figure 13.
  • the holding assembly 69 supports the holding units 71 for sliding movement inwardly/outwardly toward/away from each other.
  • the apparatus is controlled to move the holding units 71 inwardly to the closed position shown in Figure 14(c) at the time immediately prior to the insertion of a base 7 into the forward end 23 of the tube 21 and remains closed during this operation, as described below.
  • the base attachment unit 17 also comprises a base loading head 45 that picks up the base 7 from a base feed position 49 and supports the base 7 as the base loading head 45 is moved to the forward end 23 of the tube 21 and releases the base 7 when the base
  • the base loading head 45 applies a partial vacuum to the base 7 that retains the base to the head 45.
  • the base attachment unit 17 also comprises a feed assembly generally identified by the numeral 51 for supporting a stack 53 of bases 7 and delivering each base 7 in turn to the base feed position 49.
  • the feed assembly 51 is typically a standard de nesting unit designed to deliver a single base 7 from a nested stack 53 of bases 7.
  • the feed assembly 51 is positioned so that the stack 53 is an inclined orientation to facilitate gravity feeding the nested bases 7 downwardly from an upper feed end of the stack to the base feed position 49 of the stack.
  • the base attachment unit 17 also comprises a drive assembly for moving the base loading head 45 and a base 7 retained on the head 45 from the base feed position 49 to the forward end 23 of the tube 21.
  • the drive assembly moves the base loading head 45 and the retained base 7 firstly in a linear path downwardly away from the feed position 49 to a base loading position 55.
  • the drive assembly then pivots the base loading head 45 from the base loading position 55 to insert the perimeter flange 13 of the base 7 into the forward end 23 of the tube 21 at the base receiving position of the tube 21.
  • the drive assembly comprises an indexing unit (not shown) that moves the base loading head 45 in a series of steps through a base attachment sequence that moves the base loading head 45 and the retained base 7 along the above-described pathway.
  • the drive assembly comprises a first piston/cylinder assembly 61 that moves the base loading head 45 and the retained base 7 in the linear path.
  • the base loading head 45 includes a L-shaped arm that is mounted for pivotal movement to a support element.
  • the support element is connected directly to the first piston/cylinder assembly, and the first piston/cylinder assembly moves the base loading head 45 in the linear path by this connection.
  • the drive assembly also comprises a second piston/cylinder assembly 63 that is connected to the arm of the base loading head 45 and moves the arm so that it pivots about the support element from the base loading position 55 to the forward end 23 of the tube 21 and inserts the retained base 7 into the forward end 23 of the tube 21 at the base receiving position. At this point, the base loading head 45 releases the base 7.
  • the drive assembly then moves the base loading head 45 back along the pathway to the base feed position 49 of the feed unit and then repeats the above- described base attachment sequence.
  • the three welding heads of the end welding unit 31 ultra-sonically weld the base 7 to the forward end 23 of the tube 21 at three locations around the perimeter of the tube 21.
  • a required length of tube 21 with inserted and welded base 7 is then cut from the tube 21 by the cutting unit 41 and forms (a) a container tube with welded base and (b) a new forward end 23 of the tube 21.
  • the completed container tube with welded base is then removed using a standard pick and place unit (not shown).
  • Figures 16 and 17 are respective perspective and side views that show the loading head 45 picking up the base 7 from the stack 53 of bases 7.
  • Figures 18 and 19 are respective perspective and side views that show the base loading head 45 with the retained base 7 a part of the way along the linear path to the base loading position 55 for the base; 7.
  • Figures 20 and 21 are respective perspective and side views that show the base loading head 45 with the retained base 7 at the base loading position 55.
  • Figures 22 and 23 are respective perspective and side views that show the base 7 on the forward end 23 of the tube 21 and the base 7 being welded to the forward end 23 of the tube 21 after the base loading head 45 has been pivoted from the base loading position 55 shown in Figures 20 and 21 to the position shown in Figures 20 and 21.
  • Figure 24 is a side view of the base loading head 45 pivoted back to the base loading position 55 with the container comprising the length of tube 21 and the welded base 7 ready to be transported from the apparatus. In this position, the base loading head 45 is part of the way along a return path to pick up a new base 7.
  • the invention is not so limited and extends to tubes 5 having any suitable transverse cross-section.
  • the invention extends to tubes 5 that have square or rectangular cross-sections.
  • compressing the tube 21 as it runs through the tube forming unit 15 would produce an oval -type tube. This shape would be held by inserting and welding in an oval base plug.
  • multi-faceted shapes could also be produced by applying creases to the tube 21 as it runs through the tube forming unit 15. The corresponding final shape would be held in position by the inserted base 7.
  • the base loading head 45 in the embodiment of the apparatus shown in the Figures applies a partial vacuum to the base 7 that retains the base to the head 45
  • the invention is not so limited and extends to any suitable options for retaining the base 7 to the head 45.

Abstract

An apparatus for manufacturing a container that includes a side wall (5) in the form of a tube and a base (7) at one end of the tube. The apparatus includes a tube forming unit (15) for progressively folding a length of a sheet (19) of a side wall material into an elongate tube shape (21) having a forward end (23) for receiving a base (7) of the container and welding together lengthwise extending sides of the sheet to form the tube. The apparatus also includes a base attachment unit (17) for positioning a base of the container on the forward end of the tube.

Description

APPARATUS FOR MANUFACTURING A CONTAINER
TECHNICAU FIEUD
The present invention relates to an apparatus for manufacturing a container that is suitable particularly although not exclusively for packaging and transporting perishable produce, such as fruit.
The present invention also relates to a method of manufacturing the container.
The present invention also relates to the container.
BACKGROUND ART
The invention relates particularly to containers of the type that comprise a side wall in the form of a tube, a base at one end of the tube, and a removable lid at the other end of the tube.
The invention relates particularly to containers of the type that comprise a side wall in the form of a tube such as a cylindrical tube made from a plastics material, a base made from a plastics material that is welded or otherwise connected to one end of the tube, and a removable lid that is typically made from a plastics material and is adapted to be inserted into and removed from the other end of the tube to allow access to the contents of the container.
The invention provides an apparatus and a method for manufacturing these containers that is an alternative to currently-available apparatus and methods.
The above description is not to be taken as an admission of the common general knowledge in Australia or elsewhere.
SUMMARY OF THE DISCUOSURE
In general terms, the present invention provides an apparatus for manufacturing a container that includes a side wall in the form of a tube and a base at one end of the tube.
In general terms, the apparatus includes:
(a) a tube forming unit for progressively folding a length of a sheet of a side wall material into an elongate tube shape having a forward end for receiving a base of the container and welding together lengthwise extending sides of the sheet to form the tube; and (b) a base attachment unit for positioning a base of the container on the forward end of the tube.
The apparatus may also include a control system for moving the base and the tube so that that the forward end of the tube is in a required base receiving position to receive the base.
The apparatus may also include an end welding unit for welding the base to the forward end of the tube.
The end welding unit may be any suitable welding unit.
For example, the end welding unit may be an ultrasonic welding unit.
The end welding unit may be a thermal welding unit.
The end welding unit may be adapted to weld the base and the forward end of the tube together at a single location or multiple locations around the perimeter of the forward end of the tube .
The end welding unit may be adapted to weld the base and the forward end of the tube together with a continuous weld around the perimeter of the forward end of the tube.
Alternatively, the base and/or the forward end of the tube may be formed so that the base and the tube mechanically interlock together when the base is positioned on the forward end of the tube. The mechanical interlock may be via friction engagement.
For example, the base may be adapted, such as by including a perimeter flange, to be inserted into or inserted over the forward end of the tube.
The base attachment unit may include a base loading head for picking up the base from a base feed position and supporting the base and releasing the base when the base is positioned on the forward end of the tube.
The base loading head may be adapted to contact the base at the feed position and apply at least a partial vacuum to the base that retains the base to the head.
The base attachment unit may also include a feed assembly for supporting a stack of bases and delivering each base in turn to the base feed position.
The feed assembly may be a standard de-nesting unit designed to deliver a single base from a nested stack of bases. The feed assembly may be positioned so that the stack is a vertical or an inclined stack to facilitate gravity feeding bases downwardly from a higher feed end of the stack to the base feed position of the stack.
The base attachment unit may also include a drive assembly for moving the base loading head and the base from the base feed position to the forward end of the tube and for returning the base loading head (without the base) from the forward end of the tube to the base feed position.
The drive assembly may be adapted to move the base loading head in a linear path away from the feed position to a base loading position. The drive assembly may be adapted to move the base loading head in any other suitable path away from the feed position to the base loading position
The drive assembly may be adapted to pivot the base loading head from the base loading position to position the base on the forward end of the tube at the base receiving position.
The drive assembly may include an indexing unit for moving the base loading head in a series of steps in the above-described pathway between the base loading position and the base receiving position.
The base attachment unit may include an assembly for holding the forward end of the tube so that the tube has a required transverse cross-section, such as a circular transverse cross-section in the case of a cylindrical tube, while each base is positioned on the forward end of the tube.
The purpose of the holding assembly is to ensure that the cross-section of the forward end of the tube is the correct cross-section for the base. For example, in the case of a cylindrical tube, the purpose of the holding assembly is to ensure that the forward end of the tube has a circular cross-section, rather than an oblong or other cross-section, so that the cross-section is correct for the base. This is particularly important in situations whether the base is formed, for example with a perimeter flange, to be inserted into the forward end of the tube.
The holding assembly may include two holding units that are movable inwardly toward and outwardly away from the forward end of the tube, each holding unit including a surface that defines one-half of a required outer perimeter of the tube so that, in use, the surfaces are moved to contact the forward end of the tube and ensure that the tube has a required transverse cross-section, such as a circular cross-section in the case of a cylindrical tube, while each base is positioned on the forward end of the tube.
The tube forming unit may include:
(a) a drive assembly for transporting the side wall sheet material and the tube formed from the material through the tube forming unit to the base receiving position;
(b) an assembly for supporting a coil of side wall sheet material so that the sheet material can be unwound from the coil and fed through the tube forming unit,
(c) a series of lengthwise spaced-apart tube folding elements, such as pairs of rollers or other suitable elements, for progressively folding the sheet material into a tube having a required transverse cross-section with side edges of the sheet material in contact along the length of the tube, and
(d) a seam welding unit for progressively welding the side edges of the sheet material together and forming an elongate seam of the tube.
The drive assembly may comprise an indexing unit for moving the side wall sheet material and the tube through the tube forming unit in a series of steps to the base receiving position.
The indexing unit may be adapted to for moving the side wall sheet material and the tube a set required length or between index marks.
The seam welding unit may be any suitable welding unit.
For example, the seam welding unit may be an ultrasonic welding unit.
The seam welding unit may be a thermal welding unit.
The tube folding elements may be adapted to form the tube with overlapping side edges.
The tube folding elements may include a pair of lengthwise spaced-apart guide roller units for guiding the tube to the seam welding unit.
Each guide roller unit may include (i) a first set of guide rollers for contacting the outer surface of the tube and locating and guiding the tube, (ii) a first support arm supporting each first guide roller for rotation about an axis in response to contact of the first guide roller with the tube as the tube moves through the guide roller unit, and (iii) an adjustment assembly for moving each first support arm radially inwardly and outwardly between an inner position and an outer position to adjust the size of the opening for the tube. This arrangement makes it possible to use the guide roller unit with a range of different sizes of the cross-sections of the tubes.
Typically, the first guide rollers are arranged at spaced intervals around a perimeter that is transverse to the direction of movement of the tube and define an opening within the perimeter through which the tube moves.
Each guide roller unit may include:
(a) an inner support plate with a central opening for the tube to pass through and a plurality of first elongate channels extending radially outwardly from the central opening, with the first elongate channels receiving and guiding the first support arms and thereby the first guide rollers for radial movement between the retracted and the extended positions; and
(b) a pair of outer support plates on opposite sides of the inner support plate, with at least one outer support plate being mounted so that it can rotate relative to the inner support plate.
The adjustment assembly for each first guide roller may include (i) a coupling pin extending outwardly from the first support arm of the first guide roller and (ii) a plurality of spiral grooves in the rotatable outer support plate that receive the coupling pins of the first guide rollers, with each spiral groove extending between an inner end and an outer end that is located outwardly of the inner end, whereby rotation of the outer support plate relative to the inner support plate causes the coupling pins to move along the spiral grooves and thereby outwardly or inwardly and thereby moves the first support arms and the first guide rollers radially between the inner and the outer positions so that the size of the opening defined by the first guide rollers can be selected, and (c) a locking assembly for locking the inner support plate and the outer support plate together to fix the radial position of the first guide rollers and thereby fix the size of the opening.
Each guide roller unit may include a second set of the guide rollers and support arms adjacent the first set of guide rollers and support arms, whereby the first and the second sets of the guide rollers locate and guide the tube. The double set of guide rollers is advantageous in terms of ensuring there is a stable tube diameter and that the tube is guided accurately.
With this arrangement, the inner support plate may include a plurality of second elongate channels extending radially outwardly from the central opening that receive and guide the second support arms and thereby the second guide rollers for radial movement between the inner and the outer positions.
With this arrangement, the other outer support plate may be mounted so that it can rotate relative to the inner support plate, and the adjustment assembly for each second guide roller may include a coupling pin extending outwardly from each second support arm and a plurality of spiral grooves in the other outer support plate that receive the coupling pins, with each spiral groove extending between an inner end and an outer end that is located outwardly of the inner end, whereby rotation of the outer support plate relative to the inner support plate causes the coupling pins to move along the spiral grooves and thereby outwardly or inwardly and thereby moves the second support arms and the second guide rollers radially between the inner and the outer positions so that the size of the opening defined by the first guide rollers can be selected.
The second guide rollers may be off-set in relation to the first guide rollers around the perimeters of the guide rollers. This feature allows the guide rollers to maximise contact with the tube around the perimeter of the tube. This is an important consideration for larger diameter tubes.
The tube folding elements may include a seam adjustment assembly.
In a situation where the seam has overlapping side edges, the seam adjustment assembly may include a pair of gripper elements, with each gripper element being formed to engage a side edge of the sheet and to push the side edges apart to form the seam with a required overlap and to keep seam in a position that is aligned with the downstream seam welding unit.
The seam adjustment assembly may include a support assembly that supports the gripper elements for movement away from and towards each other to adjust the overlap.
The seam adjustment assembly may include any suitable means for applying a required biasing force to the gripper elements. By way of example, the seam adjustment assembly may include a fluid- actuated, typically an air-actuated, assembly for acting against the gripper elements and moving the gripper elements towards and away from each other.
Changing the pressure of the fluid to the fluid-actuated assembly makes it possible to adjust the tension applied to the sheet by the gripper elements.
Typically, the fluid-actuated assembly applies the same pressure to both gripper elements and moves the gripper elements uniformly while keeping the seam in a central position.
A benefit of this arrangement is that different width sheets does not affect the operation of the gripper elements, and the gripper elements are able to automatically accommodate different width sheets, with consequential changes in seam width for a given diameter tube, with the seam remaining in a positioned that is aligned with the downstream seam welding unit.
The seam adjustment assembly may include an assembly for moving the gripper elements laterally with respect to the direction of movement of the tube to facilitate aligning the seam with the downstream seam welding unit.
The seam adjustment assembly may be positioned between the pair of guide roller units. With this arrangement, because the guide roller units have a large contact area, it allows more pressure to be applied by the gripper elements. This reduces the accuracy required to position the gripper elements.
The apparatus may further include a cutting unit for cutting the tube a required distance from the forward end of the tube after the base has been positioned on and welded to the forward end of the tube, thereby forming a tube of a required length with an inserted base and forming the new forward end of the tube for receiving another base.
By way of example, the cutting unit may include a shear blade.
The transverse cross-section of the tube may be any suitable cross-section.
By way of example, the transverse cross-section of the tube may be circular whereby the tube is a cylindrical tube.
By way of further example, the transverse cross-section of the tube may be square. The base may include a base panel for closing the forward end of the tube and a perimeter flange that extends from the base panel.
The perimeter flange may be adapted to be inserted into the forward end of the tube.
The perimeter flange may include a lead-in edge to facilitate insertion of the flange into the forward end of the tube.
The perimeter flange may be adapted to be positioned over the forward end of the tube.
The base may be made from any suitable material.
For example, the base may be made from a plastics material.
The side wall sheet material may be a plastics material.
The side wall sheet material may be a transparent plastics material.
The present invention also provides a method of manufacturing a container that comprises a side wall in the form of a tube and a base at one end of the tube that comprises:
(a) unwinding a side wall sheet material from a coil of the material;
(b) forming the sheet material progressively into a tube having a required transverse cross-section with side edges of the sheet material in contact along the length of the tube in a tube forming unit;
(c) progressively welding the tube along the side edges and forming a seam of the tube in the tube forming unit; and
(d) positioning a base of the container on the forward end of the tube while the tube is supported by the tube forming unit at a base receiving position of the tube forming unit; and
(e) cutting the tube a required distance from the forward end to form the container having a required length and a new forward end of the tube for receiving a new base.
The method may include welding together the base and the forward end of the tube.
The method may include mechanically interlocking together the base and the forward end of the tube. The method may include holding the forward end of the tube so that the tube has a required transverse cross-section, such as a circular transverse cross-section in the case of a cylindrical tube, while each base is positioned on the forward end of the tube.
The apparatus and the method may be suitable by way of example for manufacturing a container for packaging and transporting perishable produce, such as fruit. The apparatus and the method are not confined to this application.
The present invention also provides a guide roller unit per se for guiding a lengthwise folded tube of sheet material to a seam welding unit includes (i) a first set of guide rollers for contacting an outer surface of the tube and locating and guiding the tube, (ii) a first support arm supporting each first guide roller for rotation about an axis in response to contact of the first guide roller with the tube as the tube moves through the guide roller unit, and (iii) an adjustment assembly for moving each first support arm radially inwardly and outwardly between an inner position and an outer position to adjust the size of the opening for the tube.
The first guide rollers may be arranged at spaced intervals around a perimeter that is transverse to the direction of movement of the tube and define an opening within the perimeter through which the tube moves.
Each guide roller unit may include:
(a) an inner support plate with a central opening for the tube to pass through and a plurality of first elongate channels extending radially outwardly from the central opening, with the first elongate channels receiving and guiding the first support arms and thereby the first guide rollers for radial movement between the retracted and the extended positions; and
(b) a pair of outer support plates on opposite sides of the inner support plate, with at least one outer support plate being mounted so that it can rotate relative to the inner support plate.
BRIEF DESCRIPTION OF THE DRAWING
The present invention is described further with reference to the accompanying Figures, of which:
Figure 1 is a perspective view on one embodiment of a container in accordance with the invention; Figure 2 is a side view of the container shown in Figure 1;
Figure 3 is a top view of the base of the container shown in Figure 1;
Figure 4 is a cross-section of the base component along the line C-C of Figure 3; Figure 5 is a perspective view of one embodiment of an apparatus for manufacturing the cylindrical tube of the container shown in Figures 1 and 2 and positioning the container base shown in Figures 3 and 4 on an end of the tube;
Figure 6 is a top view of the apparatus shown in Figure 5;
Figure 7 is a side view of the apparatus shown in Figure 5;
Figure 8 is a side view of section of the apparatus shown in Figure 5 that includes a pair of guide roller units and a seam adjustment assembly positioned between the guide roller units;
Figure 9 is a section along the line 9-9 of Figure 8;
Figure 10 is a perspective view of one of the guide roller units of the apparatus shown in Figure 5;
Figure 11 is an exploded perspective view of the guide roller unit shown in
Figure 10;
Figure 12 is a perspective view in diagrammatic form of the section of the apparatus shown in Figure 5 at the forward end of the apparatus which shows the tube holding assembly of the base attachment unit of the apparatus;
Figure 13 is an end view of Figure 12 with the holding assembly in an open position;
Figure 14 is a series of end views of Figure 12 that illustrates how the holding assembly corrects different out-of-shape tube cross-sections;
Figure 15 is an enlarged perspective view of the end of the apparatus shown in Figure 4 which illustrates the base attachment unit of the apparatus in an operative position in which the unit has positioned a base on the end of a cylindrical tube;
Figures 16-24 show how the base attachment unit of the apparatus picks up and moves a base from a stack and positions the base on an end of a cylindrical tube and welds the base to the tube, with:
Figures 16 and 17 being respective perspective and side views that show a loading head of the base attachment unit picking up the base from the stack of bases; Figures 18 and 19 are respective perspective and side views that show the loading head with retained base a part of the way along a linear path to a loading position for the base;
Figures 20 and 21 are respective perspective and side views that show the loading head with the retained base at the loading position;
Figures 22 and 23 are respective perspective and side views that show the base on the end of the cylindrical tube and the base being welded to the end of the tube after the loading head has been pivoted from the loading position shown in Figures 20 and 21 to the position shown in Figures 20 and 21; and
Figure 24 is a side view of the loading head pivoted back to the loading position with the base and the cylindrical tube ready to be transported from the apparatus.
DESCRIPTION OF EMBODIMENT
The embodiment of the container 3 of the invention shown in Figures 1 and 2 is suited by way of example for packaging and transporting perishable produce, such as fruit.
With reference to Figures 1 and 2, the container 3 has three main components, namely a side wall in the form of a cylindrical tube 5 made from a plastics material, a base 7 made from a plastics material welded to and closing one end of the tube 5, and a lid 9 made from a plastics material that closes the other end of the tube 5 and can be removed to allow access to the contents of the tube 5 and re-inserted to re-close the container 3.
The components are formed separately and are assembled together.
The base 7 is shown in detail in Figures 3 and 4. The base 7 includes a circular base panel 11 for closing the base end of the tube 5 and a continuous perimeter flange 13 that extends from the base panel 11 and extends into the base end of the tube 5 and is welded to the tube 5.
The invention is concerned particularly with assembling the tube 5 and the base 7 together.
An embodiment of the apparatus for assembling the tube 5 and the base 7 together is shown in Figures 5-7. Figures 8 and 9 show a seam adjustment unit of the apparatus. Figures 10 and 11 show guide roller units of the apparatus. Figures 12-14 show a tube holding assembly of the base attachment unit. Figures 15-24 show how a base attachment unit of the apparatus picks up and moves a base 7 from a stack of bases and positions the base on an end of a cylindrical tube formed in the apparatus and welds the base 7 to the tube. The seam adjustment unit, the guide roller units, and the tube holding assembly are important features of the embodiment.
The embodiment of the apparatus shown in Figures 5-7 comprises:
(a) a tube forming unit generally identified by the numeral 15 for
progressively folding a length of a sheet 19 of a side wall material that is unwound from a coil 27 into an elongate tube 21 having a forward end 23 for receiving the base 7 of the container when the forward end is at a base receiving position (as shown in Figures 5-7) and welding together lengthwise extending sides of the sheet to form the tube 21 with a lengthwise extending seam; and
(b) a base attachment unit generally identified by the numeral 17 for
positioning a base 7 of the container on the forward end 23 of the tube 21 when at the base receiving position; and
(c) an end welding unit 31 for ultra-sonic welding the base 7 to the forward end 23 of the tube 21 at three locations around the perimeter of the tube 21 at the base receiving position.
The apparatus also comprises a control system for moving the base 7 and the tube 21 so that that the forward end 23 of the tube is at the required base receiving position when the base 7 has reached this position and can receive the base 7.
The tube forming unit 15 comprises:
(a) a drive assembly (not shown) for transporting the sheet 19 and the tube 21 formed from the material through the tube forming unit 15 to the base receiving position;
(b) a coil support and unwind assembly 33 that supports the coil 27 of the sheet 19 so that the sheet 19 can be unwound from the coil 27 and fed through the tube forming unit 15,
(c) a series of lengthwise spaced-apart elements in the form of pairs of rollers 35 that are mounted for rotation about vertical axes and are positioned with one roller of each pair on opposite sides of the sheet 19 that progressively fold the sheet 19 into the tube 21, with the tube 21 having a required cylindrical transverse cross-section with side edges 37 of the sheet in contact along the length of the tube 21 with an overlap of the longitudinal side edges of the sheet, and
(d) a pair of guide roller units 65 for locating and guiding the folded tube 21 for downstream forming operations, described below;
(e) a seam adjustment assembly 67 positioned between the guide roller units 65 for controlling the overlap of the side edges 37 of the sheet 19 in the tube 21 and the position of the overlap in relation to the downstream ultra-sonic seam welding unit 39 - see below; and
(f) the ultra-sonic seam welding unit 39 mentioned in the preceding
paragraph that progressively welds the side edges 37 of the sheet 19 in the tube 21 together at the overlap and forms the elongate seam (not shown) of the tube 21 ; and
(g) a cutting unit 41 that cuts the tube 21 a required distance from the
forward end 23 of the tube 21 after the base 7 has been positioned on and welded to the forward end 23 of the tube 5 at the base receiving position, thereby forming a container tube of a required length (with the length being the distance between the forward end 23 of the tube 21 and the cutter of the cutting unit 41) with an inserted base 7 and forming the new forward end 23 of the tube 21 for receiving another base 7 after the new forward end has been moved forwardly to the base receiving position.
The drive assembly may be any suitable assembly that comprises an indexing unit (not shown) that moves the sheet 19 and the tube 21 in a series of steps of a required length through the tube forming unit 15.
With reference to Figures 8 and 9, and with particular reference to Figure 9, the seam adjustment assembly 67 includes a pair of gripper elements 75 that, in use, engage the side edges 37 of the sheet.
Each gripper element 75 is formed to engage a side edge 37 of the sheet 19 in the folded tube 21 and to push the side edges 37 outwardly to form the seam with a required overlap and to form and hold the seam in a position that is aligned with the downstream seam welding unit 39.
The gripper elements 75, as shown in cross-section in Figure 9, are L-shaped elements with hooked-ends that, in use, engage the side edge 37 of the sheet and push the sheet 19 outwardly.
The seam adjustment assembly 67 also includes a support assembly generally identified by the numeral 79 that supports the gripper elements 75 for movement away from and towards each other to adjust the overlap. The away movement is illustrated by the arrows in Figure 19.
The seam adjustment assembly also includes a fluid-actuated, typically an air- actuated, assembly for acting against the gripper elements 75 and moving the gripper elements 75 towards and away from each other in the directions of the arrows in Figure 9.
It is noted that the seam adjustment assembly may include springs or any other suitable options to applying a required biasing force to the gripper elements 75.
In use, the fluid-actuated assembly supplies fluid, such as air, under a predetermined pressure to the chamber 83, and the fluid pressure holds the gripper elements 75 apart and maintains the position of the overlapping seam. This is important in terms of the downstream seam-welding operation.
Changing the pressure of the fluid to the fluid-actuated assembly makes it possible to adjust the tension applied to the sheet by the gripper elements 75. This is important to be able to accommodate different-width sheets to form a given diameter tube 21. A benefit of this arrangement is that different-width sheets does not affect the operation of the gripper elements 75, and the gripper elements 75 are able to automatically accommodate different width sheets, with consequential changes in seam width for a given diameter tube, with the seam remaining in a position that is aligned with the downstream seam welding unit.
The seam adjustment assembly also includes an assembly generally identified by the numeral 123 for moving the support assembly 79 and the gripper elements 75 laterally with respect to the direction of movement of the tube 21. The assembly 123 includes a shaft 125 that is supported for sliding movement laterally, i.e. towards the left or the right in Figure 9 and can be locked in place in a required position. The assembly 123 also includes a body 127 that is mounted to the shaft 125 and moves with the shaft 125. The support assembly 79 and the gripper elements 75 are mounted on and move with the body 127. It can be appreciated that, in use, sliding lateral movement of the shaft 125 adjusts the lateral position of the seam to make it possible that the seam is aligned with the downstream seam welding unit 39.
The seam adjustment assembly 67 is positioned between the pair of guide roller units 65. With this arrangement, because the guide roller units 65 have a large contact area, it is possible to apply more pressure to the gripper elements 75.
With reference to Figures 10 and 11, each guide roller unit 65 includes:
(a) a first set of guide rollers 85 (i.e. first guide rollers) for contacting the outer surface of the tube 21 and locating and guiding the tube 21 as it passes through an opening 91 defined by the first guide rollers 85,
(b) a first support arm 87 (see Figure 11) supporting each first guide roller 85 for free rotation about an axis (not shown) in response to contact of the first guide roller 85 with the tube 21 as the tube 21 moves through the guide roller unit 65, and
(c) an adjustment assembly for moving each first support arm 87 radially inwardly and outwardly between an inner position and an outer position to adjust the size of the opening for the tube - this arrangement making it possible to use the guide roller unit 65 with a range of different sizes of the cross-sections of the tubes 21.
The first guide rollers 85 are arranged at spaced intervals around a perimeter that is transverse to the direction of movement of the tube 21 (this direction is indicated by the arrow in Figure 10) and define the above-mentioned opening 91 within the perimeter through which the tube 21 moves in use of the apparatus.
Each guide roller unit 65 includes:
(a) an inner support plate 93 with a central opening 95 for the tube 21 to pass through and a plurality of first elongate straight channels 97 extending radially outwardly from the central opening 95, with the first elongate channels 97 receiving and guiding the first support arms 87 and thereby the first guide rollers 85 for radial movement between the retracted and the extended positions; and (b) a pair of outer support plates 99, 101 on opposite sides of the inner support plate, 93.
The outer support plates 99, 101 are each mounted so that they can rotate relative to the inner support plate 93. The outer support plates 99, 101 can also be locked in a fixed position in relation to the inner support plate 93, as described further below
The adjustment assembly for each first guide roller 85 includes (i) a coupling pin 103 extending outwardly from the first support arm 87 of the first guide roller 85 and (ii) a plurality of spiral grooves 105 in the outer support plate 99 that receive the coupling pins 103, with each spiral groove 105 extending between an inner end 107 and an outer end 108 that is located outwardly of the inner end 107. With this arrangement, rotation of the outer support plate 99 relative to the inner support plate 93 causes the coupling pins 103 to move along the spiral grooves 105 and thereby outwardly or inwardly (depending on the direction of rotation) and thereby moves the first support arms 87 and the first guide rollers 85 radially between the inner and the outer positions. This movement allows the size of the opening 91 defined by the first guide rollers 85 to be selected. The adjustment assembly for each first guide roller 85 also includes a locking assembly (described further below) for locking the inner support plate 93 and the outer support plate 99 together, thereby to fix the radial position of the first guide rollers 85 and thereby fix the size of the opening 91.
Each guide roller unit 65 also includes a second set of the guide rollers 109 (second guide rollers 109) and support arms 111. The second guide rollers 109 are adjacent to and radially off-set from the first guide rollers 85 and support arms 87. The radial off-set of the first and second guide rollers 85, 109 can best be seen in Figure 10.
The first and the second guide rollers 85, 109 cooperate together to locate and guide the tube 21.
The double set of guide rollers 85, 109 is advantageous in terms of ensuring there is a stable tube diameter and that the tube is guided accurately.
With this arrangement, the inner support plate 93 includes a plurality of second elongate straight channels 113 extending radially outwardly from the central opening 95 that receive and guide the second support arms 111 and thereby the second guide rollers 109 for radial movement between the inner and the outer positions. As mentioned above, the outer support plate 101 is mounted so that it can rotate relative to the inner support plate 93. In addition, the adjustment assembly for each second guide roller 109 includes a coupling pin 115 extending outwardly from each second support arm 111 and a plurality of spiral grooves (not visible in Figure 11 - but the same as the grooves 105) in the outer support plate 101 that receive the coupling pins 115, with each spiral groove extending between an inner end and an outer end that is located outwardly of the inner end, whereby rotation of the outer support plate 101 relative to the inner support plate 93 causes the coupling pins 115 to move along the spiral grooves and thereby outwardly or inwardly and thereby moves the second support arms 111 and the second guide rollers 109 radially between the inner and the outer positions so that the size of the opening 91 defined by the second guide rollers 109 can be selected.
The two sets of rollers 85, 109 increases the contact along the length of the tube 21. In addition, the radial off-set of the first guide rollers 85 and the second guide rollers 109 allows the guide rollers 85, 109 to maximise contact with around the perimeter of the tube 21. In this regard, the physical size of the rollers limits the number of rollers that can be fitted around the perimeter. Maximising perimeter contact is an important consideration for larger diameter tubes.
With further reference to Figures 10 and 11, the locking assembly comprises a pair of lockable handles 107 that cooperate with part-circular-shaped slots 119 in the inner plate 99 and another pair of lockable handles 107 that cooperate with part- circular-shaped slots 119 in the outer plate 101. When engaged, the locking handles 107 hold the outer plates 99, 101 in position in relation to the inner plate 93. Therefore, in use, with the locking handles disengaged, the outer plates 99, 101 are rotated relative to the inner plate 91 to select the required diameter for the openings 91. At this point, the locking handles 107 are engaged to fix the outer plates 99, 101 to the inner plate 93 and thereby fix the diameter of the openings 91.
With reference to Figures 12-14, the base attachment unit 17 includes an assembly generally identified by the numeral 69 for holding the forward end 23 of the tube 21 so that the tube 21 has a required circular transverse cross-section while each base 7 is positioned on the forward end 23 of the tube 21. The holding assembly 69 is positioned at the downstream end of the apparatus and is not shown specifically in Figures 5-7 and 15 because it is obscured by other units at that end of the apparatus.
The purpose of the holding assembly 69 is to ensure that the cross-section of the forward end 23 of the tube 21 is the correct cross-section for the base 7.
The holding assembly 69 includes two holding units in the form of clamps 71 that are movable inwardly toward and outwardly away from the tube 21. Each holding unit 71 has a semi-circular surface 73 that defines one-half of a required outer surface of the tube 21 so that, in use, the surfaces 73 are moved to contact the outer surface of the tube 21 at the forward end 23 of the tube 21 and form around the tube 21 and bias the tube 21 into a required circular cross-section.
This action of the holding units 71 is illustrated in Figure 14 which shows diagrammatically how the inwardly-moving holding units 71 bias the out-of-round shapes in Figures 14(a) and 14(b) into the required circular cross-section shape shown in Figure 14(c). The movement of the holding units 71 is illustrated by the inwardly directed arrows shown in Figure 13.
Basically, the holding assembly 69 supports the holding units 71 for sliding movement inwardly/outwardly toward/away from each other.
In use, the apparatus is controlled to move the holding units 71 inwardly to the closed position shown in Figure 14(c) at the time immediately prior to the insertion of a base 7 into the forward end 23 of the tube 21 and remains closed during this operation, as described below.
The base attachment unit 17 also comprises a base loading head 45 that picks up the base 7 from a base feed position 49 and supports the base 7 as the base loading head 45 is moved to the forward end 23 of the tube 21 and releases the base 7 when the base
7 is positioned on the forward end 23 of the tube 21 at the base receiving position. The base loading head 45 applies a partial vacuum to the base 7 that retains the base to the head 45.
The base attachment unit 17 also comprises a feed assembly generally identified by the numeral 51 for supporting a stack 53 of bases 7 and delivering each base 7 in turn to the base feed position 49. The feed assembly 51 is typically a standard de nesting unit designed to deliver a single base 7 from a nested stack 53 of bases 7. The feed assembly 51 is positioned so that the stack 53 is an inclined orientation to facilitate gravity feeding the nested bases 7 downwardly from an upper feed end of the stack to the base feed position 49 of the stack.
The base attachment unit 17 also comprises a drive assembly for moving the base loading head 45 and a base 7 retained on the head 45 from the base feed position 49 to the forward end 23 of the tube 21.
The drive assembly moves the base loading head 45 and the retained base 7 firstly in a linear path downwardly away from the feed position 49 to a base loading position 55. The drive assembly then pivots the base loading head 45 from the base loading position 55 to insert the perimeter flange 13 of the base 7 into the forward end 23 of the tube 21 at the base receiving position of the tube 21.
The drive assembly comprises an indexing unit (not shown) that moves the base loading head 45 in a series of steps through a base attachment sequence that moves the base loading head 45 and the retained base 7 along the above-described pathway.
The drive assembly comprises a first piston/cylinder assembly 61 that moves the base loading head 45 and the retained base 7 in the linear path. The base loading head 45 includes a L-shaped arm that is mounted for pivotal movement to a support element. The support element is connected directly to the first piston/cylinder assembly, and the first piston/cylinder assembly moves the base loading head 45 in the linear path by this connection.
The drive assembly also comprises a second piston/cylinder assembly 63 that is connected to the arm of the base loading head 45 and moves the arm so that it pivots about the support element from the base loading position 55 to the forward end 23 of the tube 21 and inserts the retained base 7 into the forward end 23 of the tube 21 at the base receiving position. At this point, the base loading head 45 releases the base 7.
The drive assembly then moves the base loading head 45 back along the pathway to the base feed position 49 of the feed unit and then repeats the above- described base attachment sequence.
When the base 7 is inserted into position in the forward end 21 of the tube 5, the three welding heads of the end welding unit 31 ultra-sonically weld the base 7 to the forward end 23 of the tube 21 at three locations around the perimeter of the tube 21. A required length of tube 21 with inserted and welded base 7 is then cut from the tube 21 by the cutting unit 41 and forms (a) a container tube with welded base and (b) a new forward end 23 of the tube 21.
The completed container tube with welded base is then removed using a standard pick and place unit (not shown).
The series of steps in the above-described base attachment sequence are illustrated in Figures 16-24.
Figures 16 and 17 are respective perspective and side views that show the loading head 45 picking up the base 7 from the stack 53 of bases 7.
Figures 18 and 19 are respective perspective and side views that show the base loading head 45 with the retained base 7 a part of the way along the linear path to the base loading position 55 for the base; 7.
Figures 20 and 21 are respective perspective and side views that show the base loading head 45 with the retained base 7 at the base loading position 55.
Figures 22 and 23 are respective perspective and side views that show the base 7 on the forward end 23 of the tube 21 and the base 7 being welded to the forward end 23 of the tube 21 after the base loading head 45 has been pivoted from the base loading position 55 shown in Figures 20 and 21 to the position shown in Figures 20 and 21.
Figure 24 is a side view of the base loading head 45 pivoted back to the base loading position 55 with the container comprising the length of tube 21 and the welded base 7 ready to be transported from the apparatus. In this position, the base loading head 45 is part of the way along a return path to pick up a new base 7.
Many modifications may be made to the embodiment of the present invention described above without departing from the spirit and scope of the invention.
By way of example, whilst the container 3 shown in Figures includes a cylindrical tube 5, the invention is not so limited and extends to tubes 5 having any suitable transverse cross-section. By way of example, the invention extends to tubes 5 that have square or rectangular cross-sections. For example, compressing the tube 21 as it runs through the tube forming unit 15 would produce an oval -type tube. This shape would be held by inserting and welding in an oval base plug. By way of further example, multi-faceted shapes could also be produced by applying creases to the tube 21 as it runs through the tube forming unit 15. The corresponding final shape would be held in position by the inserted base 7.
By way of further example, whilst the base loading head 45 in the embodiment of the apparatus shown in the Figures applies a partial vacuum to the base 7 that retains the base to the head 45, the invention is not so limited and extends to any suitable options for retaining the base 7 to the head 45.

Claims

1. An apparatus for manufacturing a container that includes a side wall in the form of a tube and a base at one end of the tube, the apparatus including:
(a) a tube forming unit for progressively folding a length of a sheet of a side wall material into an elongate tube shape having a forward end for receiving a base of the container and welding together lengthwise extending sides of the sheet to form the tube; and
(b) a base attachment unit for positioning a base of the container on the forward end of the tube .
2. The apparatus defined in claim 1 includes a control system for moving the base and the tube so that that the forward end of the tube is in a required base receiving position to receive the base.
3. The apparatus defined in claim 1 or claim 2 includes an end welding unit for welding the base to the forward end of the tube .
4. The apparatus defined in claim 3 wherein the end welding unit is an ultrasonic welding unit or a thermal welding unit.
5. The apparatus defined in claim 1 or claim 2 wherein the base and/or the forward end of the tube are formed so that the base and the tube mechanically interlock together when the base is positioned on the forward end of the tube.
6. The apparatus defined in any one of the preceding claims wherein the base attachment unit includes a base loading head for picking up the base from a base feed position and supporting the base and releasing the base when the base is positioned on the forward end of the tube.
7. The apparatus defined in claim 6 wherein the base loading head is adapted to contact the base at the feed position and apply a partial vacuum to the base that retains the base to the head.
8. The apparatus defined in claim 6 or claim 7 wherein the base attachment unit includes a feed assembly for supporting a stack of bases and delivering each base in turn to the base feed position.
9. The apparatus defined in any one of claims 6 to 8 wherein the base attachment unit also includes a drive assembly for moving the base loading head and the base from the base feed position to the forward end of the tube and for returning the base loading head (without the base) from the forward end of the tube to the base feed position.
10. The apparatus defined claim 9 wherein the drive assembly is adapted to move the base loading head in a linear path away from the feed position to a base loading position.
11. The apparatus defined claim 10 wherein the drive assembly is adapted to pivot the base loading head from the base loading position to position the base on the forward end of the tube at the base receiving position.
12. The apparatus defined in any one of claims 9 to 11 wherein the drive assembly includes an indexing unit for moving the base loading head in a series of steps.
13. The apparatus defined in any one of the preceding claims wherein the base attachment unit includes an assembly for holding the forward end of the tube so that the tube has a required transverse cross-section, such as a circular transverse cross-section in the case of a cylindrical tube, while each base is positioned on the forward end of the tube.
14. The apparatus defined in claim 13 wherein the holding assembly includes two holding units that are movable inwardly toward and outwardly away from the forward end of the tube, each holding unit including a surface that defines one-half of a required outer perimeter of the tube so that, in use, the surfaces are moved to contact the forward end of the tube and ensure that the tube has a required transverse cross-section, such as a circular cross-section in the case of a cylindrical tube, while each base is positioned on the forward end of the tube.
15. The apparatus defined in any one of the preceding claims wherein the tube forming unit includes:
(a) a drive assembly for transporting the side wall sheet material and the tube formed from the material through the tube forming unit to the base receiving position;
(b) an assembly for supporting a coil of side wall sheet material so that the sheet material can be unwound from the coil and fed through the tube forming unit,
(c) a series of lengthwise spaced-apart tube folding elements, such as pairs of rollers, for progressively folding the sheet material into a tube having a required transverse cross-section with side edges of the sheet material in contact along the length of the tube, and
(d) a seam welding unit for progressively welding the side edges of the sheet material together and forming an elongate seam of the tube.
16 The apparatus defined in claim 15 wherein the drive assembly includes an indexing unit for moving the side wall sheet material and the tube through the tube forming unit in a series of steps to the base receiving position.
17. The apparatus defined in claim 16 wherein the indexing unit is adapted for moving the side wall sheet material and the tube a set required length or between index marks.
18. The apparatus defined in any one of claims 15 to 17 wherein the seam welding unit is an ultrasonic welding unit or a thermal welding unit.
19. The apparatus defined in any one of claims 15 to 17 wherein the tube folding elements are adapted to form the tube with overlapping side edges.
20. The apparatus defined in any one of the preceding claims wherein the tube folding elements include a pair of lengthwise spaced-apart guide roller units for guiding the tube to the seam welding unit.
21. The apparatus defined in claim 20 wherein each guide roller unit includes (i) a first set of guide rollers for contacting the outer surface of the tube and locating and guiding the tube, (ii) a first support arm supporting each first guide roller for rotation about an axis in response to contact of the first guide roller with the tube as the tube moves through the guide roller unit, and (iii) an adjustment assembly for moving each first support arm radially inwardly and outwardly between an inner position and an outer position to adjust the size of the opening for the tube.
22. The apparatus defined in claim 21 wherein the first guide rollers are arranged at spaced intervals around a perimeter that is transverse to the direction of movement of the tube and define an opening within the perimeter through which the tube moves.
23. The apparatus defined in claim 21 or claim 22 wherein each guide roller unit includes:
(a) an inner support plate with a central opening for the tube to pass through and a plurality of first elongate channels extending radially outwardly from the central opening, with the first elongate channels receiving and guiding the first support arms and thereby the first guide rollers for radial movement between the retracted and the extended positions; and
(b) a pair of outer support plates on opposite sides of the inner support plate, with at least one outer support plate being mounted so that it can rotate relative to the inner support plate.
24. The apparatus defined in claim 23 wherein the adjustment assembly for each first guide roller includes (i) a coupling pin extending outwardly from the first support arm of the first guide roller and (ii) a plurality of spiral grooves in the rotatable outer support plate that receive the coupling pins of the first guide rollers, with each spiral groove extending between an inner end and an outer end that is located outwardly of the inner end, whereby rotation of the outer support plate relative to the inner support plate causes the coupling pins to move along the spiral grooves and thereby outwardly or inwardly and thereby moves the first support arms and the first guide rollers radially between the inner and the outer positions so that the size of the opening defined by the first guide rollers can be selected, and (c) a locking assembly for locking the inner support plate and the outer support plate together to fix the radial position of the first guide rollers and thereby fix the size of the opening.
25. The apparatus defined in claim 24 wherein each guide roller unit includes a second set of the guide rollers and support arms adjacent the first set of guide rollers and support arms, whereby the first and the second sets of the guide rollers locate and guide the tube.
26. The apparatus defined in claim 25 wherein the inner support plate includes a plurality of second elongate channels extending radially outwardly from the central opening that receive and guide the second support arms and thereby the second guide rollers for radial movement between the inner and the outer positions.
27. The apparatus defined in claim 26 wherein the other outer support plate is mounted so that it can rotate relative to the inner support plate, and the adjustment assembly for each second guide roller includes a coupling pin extending outwardly from each second support arm and a plurality of spiral grooves in the other outer support plate that receive the coupling pins, with each spiral groove extending between an inner end and an outer end that is located outwardly of the inner end, whereby rotation of the outer support plate relative to the inner support plate causes the coupling pins to move along the spiral grooves and thereby outwardly or inwardly and thereby moves the second support arms and the second guide rollers radially between the inner and the outer positions so that the size of the opening defined by the first guide rollers can be selected.
28. The apparatus defined in claim 27 wherein the second guide rollers are off-set in relation to the first guide rollers around the perimeters of the guide rollers.
29. The apparatus defined in any one of claims 15 to 28 wherein the tube folding elements include a seam adjustment assembly.
30. The apparatus defined in claim 29 wherein, in a situation where the seam has overlapping side edges, the seam adjustment assembly includes a pair of gripper elements, with each gripper element being formed to engage a side edge of the sheet and to push the side edges apart to form the seam with a required overlap and to keep seam in a position that is aligned with the downstream seam welding unit.
31. The apparatus defined in claim 30 wherein the seam adjustment assembly includes a support assembly that supports the gripper elements for movement away from and towards each other to adjust the overlap.
32. The apparatus defined in claim 30 or claim 31 wherein the seam adjustment assembly includes a fluid-actuated, typically an air-actuated, assembly for acting against the gripper elements and moving the gripper elements towards and away from each other.
33. The apparatus defined in any one of the preceding claims further includes a cutting unit for cutting the tube a required distance from the forward end of the tube after the base has been positioned on and welded to the forward end of the tube, thereby forming a tube of a required length with an inserted base and forming the new forward end of the tube for receiving another base .
34. The apparatus defined in any one of the preceding claims wherein the transverse cross-section of the tube is circular whereby the tube is a cylindrical tube.
35. The apparatus defined in any one of the preceding claims wherein the base includes a base panel for closing the forward end of the tube and a perimeter flange that extends from the base panel.
36. The apparatus defined in claim 35 wherein the perimeter flange is adapted to be inserted into the forward end of the tube.
37. The apparatus defined in claim 36 wherein the perimeter flange includes a lead- in edge to facilitate insertion of the flange into the forward end of the tube.
38. The apparatus defined in any one of claims 1-36 wherein the perimeter flange is adapted to be positioned over the forward end of the tube.
39. A method of manufacturing a container that comprises a side wall in the form of a tube and a base at one end of the tube that includes:
(a) unwinding a side wall sheet material from a coil of the material;
(b) forming the sheet material progressively into a tube having a required transverse cross-section with side edges of the sheet material in contact along the length of the tube in a tube forming unit;
(c) progressively welding the tube along the side edges and forming a seam of the tube in the tube forming unit; and
(d) positioning a base of the container on the forward end of the tube while the tube is supported by the tube forming unit at a base receiving position of the tube forming unit; and
(e) cutting the tube a required distance from the forward end to form the container having a required length and a new forward end of the tube for receiving a new base.
PCT/AU2019/050023 2018-01-15 2019-01-15 Apparatus for manufacturing a container WO2019136530A1 (en)

Priority Applications (3)

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US16/961,924 US11420400B2 (en) 2018-01-15 2019-01-15 Apparatus for manufacturing a container
EP19738420.9A EP3740371A4 (en) 2018-01-15 2019-01-15 Apparatus for manufacturing a container
AU2019207533A AU2019207533A1 (en) 2018-01-15 2019-01-15 Apparatus for manufacturing a container

Applications Claiming Priority (2)

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AU2018900115A AU2018900115A0 (en) 2018-01-15 Apparatus for Manufacturing a Container

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GB1509932A (en) * 1974-05-31 1978-05-04 Yoshino Kogyosho Co Ltd Automatic machine for forming plastics tubes
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GB2156268A (en) * 1984-03-26 1985-10-09 Vercon Inc Manufacturing thermoplastic tubular containers
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US20200384702A1 (en) 2020-12-10
AU2019207533A1 (en) 2020-07-02
US11420400B2 (en) 2022-08-23
EP3740371A4 (en) 2022-02-23

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